Digest
Several errors lead to a hydrogen leak & fire — Process Safety Beacon, September 2025
Several errors lead to a hydrogen leak & fire — Process Safety Beacon, September 2025
- CCPS
- Digest
- Process Safety Beacon September 2025
- Hot Work and FireHuman FactorsHydrocarbon ReleaseProcess Safety
- ExplosionFireHuman factorsHydrogen safetyLoss of containment
- Fluid transferInspection and maintenance
- Process pipework and pipelinesValve
- Competence and trainingLockout and tagoutOperating and work proceduresSafety communication
- Onshore facility
Summary
This bulletin examines a hydrogen filling incident in Santa Clara in which a trainee inadvertently restarted filling while piping was dismantled for repair. Escaping hydrogen ignited, producing a deflagration and jet fire. It emphasises isolation procedures, authorised repairs, understandable controls and clear instructions for newer employees.
Classifications: Explosion; explosive atmospheres.
Classifications: Fire; fire safety.
Classifications: Human factors; human performance; ergonomics.
Classifications: Hydrogen safety.
Classifications: Loss of containment; containment loss.
Classifications: Fluid transfer; fluid loading; fluid offloading.
Classifications: Inspection and maintenance; asset inspection; equipment maintenance.
Classifications: Process pipework and pipelines; process piping.
Classifications: Valve; valves.
Classifications: Competence and training; competency assurance; safety training.
Classifications: Lockout and tagout; LOTO; lockout/tagout.
Classifications: Operating and work procedures.
Classifications: Safety communication; toolbox talk; toolbox talks.
Classifications: Onshore facility; onshore plant.
Summary
One-page Beacon on how multiple errors combined to cause a hydrogen leak and fire.
Process Safety Beacon September 2025. Themes: hot work and fire, human factors, hydrocarbon release, process safety.